Journal of Manufacturing Processes 66 (2021) 228–237

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Journal of Manufacturing Processes

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Review

Additive manufacturing of metallic based on extrusion process: A review

Aghnia Ilmiah Nurhudan a, Sugeng Supriadi a, b, *, Yudan Whulanza a, b,
Agung Shamsuddin Saragih a, b
a
Department of Mechanical Engineering, Faculty of Engineering, Universitas Indonesia, Kampus UI Depok, 16424, Indonesia
b
Research Center for Biomedical Engineering, Faculty of Engineering, Universitas Indonesia, Kampus UI Depok, 16424, Indonesia

A R T I C L E I N F O A B S T R A C T

Keywords: Additive manufacturing is a technology employed to create a three-dimensional object taking advantage of a
Additive manufacturing Computer-Aided Design. This technology is also known as 3-D printing. This technology can be applied to many
Debinding kinds of materials such as plastic, metals, alloy steels, ceramics, glass or a combination of any of them. However,
Fused deposition modeling
currently, there are many talks on metallic materials as the materials employed in the additive manufacturing
Sintering
because metals possess superior physical properties. Moreover, there are various kinds of 3-D Printing techniques
that can be applied to metallic materials. Nevertheless, Fused Deposition Modelling (FDM) is one of these
techniques that employ an extrusion-based process which is capable of fabricating metallic parts. The metallic
printed part of FDM is called a green part, consist of the powder and binder system. Before this part is used, it
requires a post-operation process, such as a debinding process to remove the binder system and the sintering to
compress the object so as to be more reliable. The final part is called a brown part which is that mechanical
properties are affected by the parameter of process and the characteristic of material. This review paper will
present current state of the quality of printed part that fabricating with an additive manufacturing employing the
extrusion material techniques, such as fused deposition modeling based on the mechanical properties of final
part.

1. Introduction time by planning a travel path to create multilayer by multilayer [6].

Several materials can be used in Additive Manufacturing, such as metals,
Additive manufacturing (AM) is a fabrication technology employed ceramics, glass, plastic, or a combination of any of them. These materials
to create a layer-by-layer object using a Computer-Aided Design (CAD); can be form of powder, a feedstock, or a filament [7].
moreover, it has other capabilities such as creating a shape complexity, The first development of Additive Manufacturing was initiated by
hierarchical complexity, material complexity, and functional Hideo Kodama in 1980 when developed an ultraviolet light to harden
complexity [1]. Various layer by layer fabrication are applied with and create the solid part. Then, in 1990, Charles Hull developed ster­
extrusion-solidification method, adhesive-curing method, and direct eolithography (SLA). Furthermore, in 1991, Scott Crump developed
sintering or melting. While the improvement of capabilities, that also fused deposition modelling (FDM). They used polymer in their devel­
continues to decreased the fabrication time as well as saving energy opment. In the early 1990s, Ely Sachs and co-workers developed a
consumption by planning the path strategy to reducing the building time binder jetting employing metal materials. Then, Carl Deckard developed
[2]. Machine learning method can use of that process to see the direct metal laser sintering (DMLS) capable of delivering a high energy
complexity relation between design and performance of part [3]. source used to process metal powder. That was an extension to the se­
Additive manufacturing is conducted without any manufacturing lective laser sintering (SLS) metal. Since the onset of these de­
processes, such as planning, tooling, and fixtures [4]. Additive velopments, there have been significant other new developments and
manufacturing (AM) is a technology arising against engineering in­ applications of additive manufacturing [8].
terests since it can manufacture a component with complex geometry Many people have recently conducted studies on metallic materials.
[5]. Not only do people employ this process to reduce the costs of Those materials have a higher level of micro-changes accuracy when
manufacturing processes, but they also use it to reduce the fabrication exposed to a high temperature. The findings of the reviews on these

* Corresponding author at: Department of Mechanical Engineering, Faculty of Engineering, Universitas Indonesia, Kampus UI Depok, 16424, Indonesia.
E-mail address: [email protected] (S. Supriadi).

https://doi.org/10.1016/j.jmapro.2021.04.018
Received 17 December 2020; Received in revised form 1 April 2021; Accepted 9 April 2021
Available online 18 April 2021
1526-6125/© 2021 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
A.I. Nurhudan et al. Journal of Manufacturing Processes 66 (2021) 228–237

metallic materials have been applied to various Additive Manufacturing solidification of chemicals. The tube is made of a mixture of powder and
Techniques [9], such as Selective Laser Sintering (SLS) [10–14], Direct binder that will be inserted into the extruder, where the extruder has
Metal Deposition (DMD) [15–19], Shape Metal Deposition (SMD) [20], cavity-like cartridges. This construction is equipped with a heating
Electron Beam Melting [21–25], and Plasma Deposition Manufacturing element; therefore, the rod material will undergo a plasticizing process
[26]. They are Additive Manufacturing Techniques familiarly applied to until it can be pushed out of the nozzle [45,46]. This type’s main com­
these metallic materials. However, it requires such a high production ponents are the actuator, the plunger, the heater, the nozzle, and the bed
cost to produce an object deriving from a metallic material with those (Fig. 1).
techniques; moreover, the manufactured items’ prices are relatively The plunger is a part employed to push the material into the heater.
high, too [27,28]. On the contrary, the heater is a component capable of heating the ma­
Furthermore, the Additive manufacturing (AM) with extrusion- terial, so the material can be melted and smoothly go down to the nozzle.
solidification method have equipment that cheaper than other, low- The nozzle is a material discharge that will form the material layer-by-
cost production, mechanically simple, and easily operated. Various layer on the bed. This type is identical to that of a plunger-shaped
materials can be employed, include metallic materials [29–31]. This extruder since it is in the form of a rod. The booster should be strong
method consists of three kind, such as Filament-based, Syringe-based, enough to be able to push out the material heading through the nozzle.
and Screw-based. This technique involves making a 3-D object by soft­ The flow printing process starts when the material went through into
ening the materials, then extruded and deposited layer upon layer [32]. the guide bush and heating room. Then the plunger pushes the material
The most widely used is filament-based and one of these is Fused while the heating process is going on. The heat temperature should be
Deposition Modelling (FDM) technique. The support structure is higher than the melting point of the material. When the material is
required on this technique. It is affects to the mechanical properties of melted, it can flow into the nozzle and create an object as a path
the final part since that part is printed upon them. The same part’s final planning.
mechanical properties will be different if employed with a different type
of the support structure. The most suitable support structure for all
methods and kinds of objects is line type [33].
But this technique has some limitations, such as lack of solvent for
drug, poor surface finish, dimensional inaccuracy, low resolution, poor
mechanical properties that would be attributed to the defect like high
porosity, insufficient compaction, and adhesion between the filament
layer. It requires such an excellent post-manufacturing treatment before
the part is used [29,34–40]. In other conditions, we should adjust the
support structure on FDM according to our need to create good quality
results by planning the parameter [41]. The support structure also
challenges the removal process supposed to be removable without
making a building material broken. [42]. However, if FDM uses a
metallic material, there is a binder system serving to support the fabric.
The binder will be removed by the debinding process, and the part will
be made denser by the sintering process [43]. When this technology is
employed, shrinkage also emerges after sintering process [44].
This review will discuss the mechanical properties of Additive
Manufacturing (AM) with an Extrusion Process like Fused Deposition
Modelling (FDM) that employs a metallic material. The mechanical
Fig. 1. Material Extrusion with Plunger-based.
properties in this case traced based on material properties, printing
parameter, debinding parameter, and sintering parameter. The variation
2.2. Filament-based type
of that can make the different quality of the printed part. This review
also will compare with the other AM techniques that familiarly used
Stratasys, Ltd. first patented this Extrusion with Filament-based
metallic materials.
Materials. Fused Filament Fabrication (FFF) another name of FDM
This review paper consists of six sections. Section 2 explain the Fused
that material type is of which is filament. That is a prevalent 3D printing
Deposition modelling in generally. Section 3 explain the composition of
technique applying a material extrusion technology since the process is
metallic materials. Section 4 explain the printing process of metallic
safe, the fabrication process is simple, and the employed components are
materials that showed in section 2. Section 5 explain the post processing
cheap. There are various materials in the forms of a filament. In this
process of printed part that produced in the section 2, such as debinding
process, the material is driven with a roller extruder so that the filament
process and sintering process. In this section also show the mechanical
can go down to the nozzle [47]. The extrusion’s main components with a
properties of the final part. Finally, on section 6 will discuss about the
filament-based are the feed roller, the heater, the nozzle, and the bed
mechanical properties, current condition, challenge and further
(Fig. 2).
research.
The feed roller is a part employed to push the material into the
heater. The heater is a component used to make the material melt and go
2. Additive manufacturing based on extrusion process
to the nozzle, and the nozzle is a material discharge that will form the
material layer-by-layer on the bed. This type is identical to that of the
Additive manufacturing based on extrusion proses consists of three
roller-shaped thruster due to the fact that the filament resembles the
kind, such as Filament-based, Syringe-based, and Screw-based. The
formation of a wire. The flow printing process starts when the feed roller
following are detailed of that mechanism.
extrudes the filament into the heating room while the heating process is
going on. Heat temperature should be higher than the material’s melting
2.1. The syringe or Plunger-based type
point to make the material flow into the nozzle. When it happens, the
material will create an object as the path planning that has been made
Desktop Metal Inc. and Markforged are two companies
before.
manufacturing an additive manufacturing machine. The material type
from one of those machines is a bar feedstock produced from the

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Fig. 2. Material extrusion with filament-based.

2.3. Screw-based type hanging the heater system and nozzles serving as the holes for the ma­
terial discharge. In this type, the materials are usually in the forms of
Screw-based extrusion is not so different from the other extrusion granule feedstock so that they will be able to fill the thrust space be­
types. The material entering the system is in the form of a granule tween the screws. The system is also deemed the most stable; moreover,
feedstock that will enter the conveyor construction in the form of a the heating rate can be better organized. The flow printing process
screw that will pump up the material into the nozzle. The process is started when material through into the screw system from the hopper.
deemed to be the most stable due to its more continuously secure pro­ While material screwing the material, the heating process is going on.
cess. Moreover, the material will optimally be distributed to the nozzle. Heat temperature should be higher than the material’s melting point to
However, the pellet size must be controlled to regulate the flow of the make the material flow into the nozzle. When it happens, the material
production process [48]. Below are the main components of the will create an object as the path planning that has been made before.
screw-based material extrusion (Fig. 3).
The components consist of motors serving as the movers, hopper as 3. Fused Deposition Modelling (FDM)
the containers serving as the material storage, screws serving as the
driving material to be connected to the motor, cartridge heaters serving Fused Deposition Modeling (FDM) is the most widely used and
as the heating elements employed to melt the material, holder for commercialized technique that applying layer by layer extrusion process
using filament-based type. The first FDM machine was manufactured by
Stratasys, Inc. FDM is a process of pressing a material towards the nozzle
to form a three-dimension product in the form of a coating. This tech­
nology is suitable for various materials; moreover, the materials range
from metallic materials to non-metallic ones [49]. FDM is commonly
used for prototyping. However, nowadays, it is also used for a functional
prototype, manufacturing tooling, and end-use parts [50].
The manufacturing process of FDM consists of preparing material,
printing process, and post-operation process. When FDM uses metallic
material, the post-operation process consists of debinding and sintering
process. Fig. 4 below shows an overview of that process.
The preparing material is processed by mixing the powder and the
binder system. The result of this process can be a feedstock or a filament
then use for the printing process. The printed part is called the green
part. Before this part is used, it requires a post-operation process, such as
a debinding process to remove the binder system and the sintering to
compress the object to be more reliable.
This technique has an opportunity to a lot of material waste from
support structure if not manage well. Therefore, there are three methods
that can be used to manage that material waste namely optimizing the
build orientation of the part, using the cheaper material than the
building part for the support structure, and choosing the best type of the
support structure. The other way is improving the printable bridge
Fig. 3. Material extrusion with screw-based.

Fig. 4. Manufacturing process of Fused Deposition Modelling (FDM).

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Table 1
Material and Composition of Powder Content.

Powder Particle Compound Properties (%)

Brand/
Material Content Size Carbon Chromium Copper Iron Manganese Molybdenum Nickel Niobium Phosphorus Silicon Sulfur Ref
Developed
(%) (μm) (C) (Cr) (Cu) (Fe) (Mn) (Mo) (Ni) (Nb) (P) (Si) (S)

Stainless Sandvik Osprey 55 D10 of 0,010 15,5 – 17,5 3,0 – 5,0 71,85 0,76 0,30 3,0 – 5,0 0,15 – 0,45 0,040 0,84 0,030 [55,
steel Ltd., UK 4,2 56]
(17- D50 of
4PH) 12,3
D90 of
28,2
Stainless Micro-Melt® 316 55 17,7 0,030 17-19 0,50 62 2,00 2,25 – 3,50 13 - 15 0,10 0,025 0,75 0,010 [57,
steel L, Carpenter 58]
(316 L) Technology Corp.,
USA
231

Chromium Nickel Cobalt

Stainless BASF Ultrafuse
(Cr) (Ni) (Co) [59,
steel 316 LX metal 88 30 - 50
0 ≤ Co ≤ 60]
(316 L) filament 0 ≤ Cr ≤ 25 0 ≤ Ni ≤ 20
1
D10 of 7 Aluminum Vanadium Iron Carbon Oxygen Nitrogen Hydrogen
Nickel (Ni) Others Total Others
Titanium Praxair Surface D50 of (Al) (V) (Fe) (C) (O) (N) (H)
[61,
(Ti-6Al- Technologies, 59 13
3,50 – 62]
4 V) Indianapolis, IN D90 of Bal. 5,50 – 6,50 0,25 0,08 0,2 0,05 0,015 0,1 0,4
4,50
21
Kalium +
Aluminum Calcium Cobalt Chromium Iron Molybdenum Magnesium Sulfur Silicon Wolfram
Natrium
Titania US Research 0.03 (Al) (Ca) (Co) (Cr) (Fe) (Mo) (Mg) (S) (Si) (W) [63,
65 (K + Na)
(TiO2) Nanomaterials Inc (30 nm) 64]
≤
≤ 0,003 ≤ 0,005 ≤ 0,01 ≤ 0,005 ≤ 0,005 ≤ 0,005 ≤ 0,005 ≤ 0,01 ≤ 0,005 ≤ 0,01

Journal of Manufacturing Processes 66 (2021) 228–237

0,003
Average ratio 64

Notes: “D” is diameter symbol for particle size of powder.

A.I. Nurhudan et al. Journal of Manufacturing Processes 66 (2021) 228–237

length by decreased the print temperature, increased fan speed, and example, the microstructure of stainless steel 17-4 PH contained
decreased print speed [51]. martensite laths, little amount of M7C3, and NbC carbides as role as
strengthening element, also have no outside defect after sintering pro­
4. The composition of metallic materials cess [55,65]. Stainless steel 316 L able to printed by simple 3D FFF
printer, simple lab setup, sintered in an inexpensive vacuum furnace,
Metals are materials with superior physical properties. A metallic and the component have a high density [57]. This material has excellent
material can be employed in various sectors with a high degree of mechanical properties, machinability, weldability, high corrosion
complexity and used in multiple manufacturing ranges from a human resistance and one of the most widely used biomaterials for implants
organ, such as implant until a spare part of a spacecraft. Those metals are [65,66]. Titanium Ti-6Al-4V is the material used in almost 60 % of all Ti
aluminum alloys, cobalt-based alloys, nickel-based alloys, stainless Materials applications [67]. This material has good biocompatibility,
steel, and titanium alloys [52]. corrosion resistance, and high specific strength, and widely use for the
The printing result of Additive manufacturing (AM) based on medical part [68].
extrusion-process that uses a metallic material is called the green part. It As seen above, the powder content’s composition ratio to the binder
consists of the powder and binder system. system is 64:36 on average. Each brand carries out its own trials to
create the best ratio since this ratio is a critical section; moreover, it
should be found in a suitable composition. If there is too little powder
4.1. Powder content content, it may result in a deformation during the sintering process. If
there is too much powder content, it may result in lead that voids the
The metal material used consists of a powder and a binder system. prevailance after the sintering process [69]. Moreover, the process­
The powder is a metal with high consistency, and the binder is an ability, characteristic, material density, viscosity, mixing torque and
organic multi-component. Powder and binder are mixed to form a critical powder loading are influenced by its composition, particle size,
feedstock or filament then. The powder content usually ranges from 50 and distribution [70,71]. As a performance benchmark for metal ma­
to 65 % in volume; there is also 80 % powder for some materials. The terials to be used, the following are the mechanical properties of raw
powder consistency can affect the sintering result. The more powder, the materials such as sheets, rods, etc (Table 2).
product will be denser [53]. Powder content is also instrumental in The table above shows the mechanical properties of the same name
improving the mechanical and tribological of material. The kind of material but the different type. The table also compares the quality of
metal and each characteristic will have a different effect on the prop­ raw materials employed in the additive manufacturing process and other
erties [54]. The table below shows some of the metallic materials used to processes.
create an object with Fused Deposition Modelling technique as one of
the Additive Manufacturing types based on extrusion-process (Table 1).
There are various kind of metal materials, such as titanium alloy, 4.2. Binder system
tungsten alloy, aluminum, etc. that used by FDM. The four materials in
the table above are the most mainly used. That has completely process The binder system material can be in the forms of a polymer, a wax,
start from material production, product printing, removing the binder, and an additive, each with different compositions. In general, the binder
sintering process, until testing the resulting object. system consists of the primary material, backbone, and additional ad­
Each material has advantages that make an object created well. For ditives. Each of the types has its fraction. The main material accounts for

Table 2
Mechanical Properties Material based on United Performance Metals.
Material Ultimate Tensile Strength Yield Strength Elongation at Break Hardness Density Ref
(MPa) (MPa) (%) (g/cm3)

Stainless steel 1310 1170 10 40 HRC 7,80 [72,73]

(17-4PH/ ASTM A564)
Stainless steel 485 170 40 95 HRB 8,00 [74,75]
(316 L/ ASTM A240)
Titanium 860 758 8 – 4,43 [76,77]
(Ti-6Al-4 V/ ASTM F1108)
Titania 895 828 10 – 4,10 [62]
(TiO2/ ASTM B348)

Table 3
The Composition of Binder System.
Type Material Brand/Developed Main component(50− 90%) Backbone(0− 50%) Additive Ref.
(0− 10%)

Filament Stainless steel (17- Powder: Sandvik Osprey Ltd., UK Thermoplastic elastomer Grafted Polyolefin None [55]
4PH) (TPE)
Powder: Micro-Melt® 316 L, Thermoplastic elastomer
Filament Stainless steel (316 L) Grafted Polyolefin None [57]
Carpenter Technology Corp., USA (TPE)
Polypropylene (PP)
Dioctyl Phthalate
(DOP)
Filament Stainless steel (316 L) BASF Ultrafuse 316 LX metal filament Polyformaldehyde (POM) None [59]
Dibutyl Phthalate
(DBP)
Zinc Oxide
Powder: Praxair Surface Technologies, The Multi-component polymer binder produces the feedstock. It has the
Filament Titanium (Ti-6Al-4 V) [61]
Indianapolis, IN viscosity under 1000 Pa.s and the shear rate under 1000 1/s at 240 ◦ C.
Filament Titanium (Ti-6Al-4 V) American Elements Polyolefin [78]
Powder Titania (TiO2) Powder: US Research Nanomaterials Inc. Bentonite Powder-quest White 3411-01 [63]

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the Fused Deposition Modelling technique (Table 4).

The table above shows that there are some materials fabricated with
different parameters and machine types. The parameter is planned to
create an object optimally. Therefore, when a different object is created,
the parameter will be adjusted. It also occurs when the object is created
with a different machine type. This parameter is significantly influenced
the mechanical properties of printed part [85].
When the fabricating process, there is not only created the part but
also created the support structure that according to the overhanging of
the part. Between main part and support part use the different material.
Fig. 5. Generating G-Code. The removal process of support structure requires of manual work,
ground, or milled after printing [41].
50− 90 % of the binder system material, the backbone accounts for 0− 50
%, and the additional additives account for 0− 10 % of the binder system 6. Post-operation process
material. Below are some examples of the following binder system ma­
terials with the composition of each type (Table 3). 6.1. Debinding
The table above shows that there are various types of the binder
system providing sufficient attention to the composition of the material, The binder material should be removed in these parts. That can be
the accuracy of the saved shape in the intermediate stages, and the conducted through a debinding process with the materials decay [86].
quality of the product in the final stage depends on it [79]. Moreover, There are several debinding processes such as the thermal, solvent, and
the binder composition affects the rheology of the material, solvent catalytic debinding processes. Besides their media, what makes these
debinding, porosity and microstructure. When the binder system has a three types differ from one another includes the process. In the thermal
high composition, the melt flow rate will have a high value, too. It is debinding process, the temperature ranges from 60 ◦ C to 600 ◦ C
important for us to know the characteristics and compositions of the depending on the debinding composition that is employed. In the sol­
content to ensure its suitability to the needed component [80]. vent debinding process, heptane or trichloroethane solvents can be
employed.
5. Printing process Moreover, in the catalytic debinding process, nitric or oxalic acid can
be employed at temperatures ranging from 110 ◦ C to 150 ◦ C [87]. The
The critical point in the fabrication process employing this technol­ thermal debinding process is used the most widely. We conduct the
ogy is generating a G-code or building a rapid manufacturing model. process by heating it at a specific temperature and holding it at a certain
Fig. 5 below shows the steps of generating the G-code. This process uses period of time. The duration of the detention is supported by the ma­
the software to slicer the 3D CAD data. terial contents contained in the feedstock. The employed temperature
This process uses a slicer software to create the path printing pro­ must not be too high since it will make the material decomposed into
gram. Several parameters are used to generate the plan, such as the carbon [88]. Below is the parameter of debinding using the fused
printing angle, the layer thickness, the fill rate, the nozzle, the bed deposition method (Table 5).
temperature, and so on [81]. When the object starts to be built, the
parameter should be set up before it generates the G-code data. Every 6.2. Sintering
material has its parameter, and some of them are critical parameters
such as the melting temperature of the material, the nozzle temperature, The green part will turn into a brown part in the next stage that will
and the bed temperature. By planning the parameter, this software can subsequently go through a sintering process. It is part of the compaction
plan such strategies to provide the results with more accuracy, good processes that have shed the binder material. Therefore, in this process,
quality, and efficiency [82]. Below is the parameter of fabricating using shrinkage will occur, and theoretically, the density will rise to 99 %.

Table 4
Parameter of Fabricating using Fused Deposition Method.
Parameter
Machine of Fused Melting Nozzle Bed Nozzle Infill Fill Printing Infill Flowrate Layer
Material Deposition Modeling Temp. Temp. Temp. Diameter (%) Angle Perimeter Printing Multiplier Thickness Ref.
Technique (◦ C) (◦ C) (◦ C) (mm) (◦ ) Speed Speed (%) (mm)
(mm/s) (mm/s)

Stainless Duplicator i3 v2 – 235 100 0.6 100 45 60 80 175 0.2 [55]

steel
(17-
4PH)
Stainless Prusa i3 MK2 220 250 – 0.6 100 45 – – 125 0.2 [57]
steel
(316 L)
Stainless CoLiDo metal 3D 165 230 90 0.4 – – 30 – – 0.2 [59,
steel printer 60,
(316 L) 83]
Titanium Pulse 3D printer from – ≤295 ≤120 0.4 100 – ≤250 – – – [61,
(Ti-6Al- MatterHackers 84]
4 V)
Titanium The – 190–210 60 0.4 – – 50 – – 0.1 [78]
(Ti-6Al- Renkforce 1000
4 V)
Titania – – – – 2 – – – – – 2 [63]
(TiO2)

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Table 5
Parameter of Debinding using Fused Deposition Modeling.
Parameter Solvent Deibinding Parameter Thermal Debinding
Material Media Temp. ( C)
◦
Time (h) Vacuum furnace Temp. Time (h) Ref
(mbar) (◦ C)

Stainless steel Cyclohexane 70 – – – – [55]

(17-4PH)
3
Stainless steel Cyclohexane 65 24 10− - 10-5 374 - 750 1,5 [57]
(316 L)
Stainless steel Nitrogen 120 8 – – – [59]
(316 L)
Titanium Acetone 60 24 – 40 6 [78]
(Ti-6Al-4 V)
Titania Water – – – – – [63]
(TiO2)

Table 6
Parameter of Sintering using Fused Deposition Modeling.
Parameter
Material Vacuum Atmosphere (mbar) Media Temperature (◦ C) Time Ref
(h)

Stainless steel – Hydrogen 1380 5 [55]

(17-4PH)
− 3
Stainless steel 10 Vacuum 1360 2 [57]
(316 L)
Stainless steel – Argon 1360 2 [59]
(316 L)
Titanium – Argon 1340 1.5 [78]
(Ti-6Al-4V)
Titania – Atmosphere 1300 4 [63]
(TiO2)

There are six mass transfer mechanisms in this sintering process, namely recoater arm to move the metal powder to the powder bed. After that
surface diffusion, lattice diffusion, grain boundary diffusion, laser beam will created the part as the program on machine until the
evaporation-condensation, viscous flow, and plastic flow [89]. After the whole part created. The resulting part is in the form of sintered part [66,
sintering process, porosity ranging from 12 % to 20 % will probably 92].
occur, too, depending on how high the temperature is used. There are Moreover, this table also shows that the Stainless steel 17-4 PH and
various gases employed in this sintering process, such as argon, Stainless steel 316 L processed with DMLS or SLS have a higher tensile
hydrogen, and nitrogen. Several factors significantly affect the sintering strength than that FDM. The tensile strength is affected by the temper­
process, such as the heating rate, the heating temperature, the length of ature gradient during the printing process. At the same time, the tem­
time of the sintering process, and the sintering atmosphere. perature gradient is depending on the duration of the building process.
Moreover, they will affect the microstructure, size, porosity, final The layer thickness also affected the tensile strength. When the layer
level of density, and nitrogen’s final content. Several factors will affect thickness is set at a high value, it will create a gap between layers. That
the value; therefore, the results will be modified to enhance the prod­ makes a porosity value increased.
uct’s final quality [88]. Below is the parameter of sintering using the Elongation at break is a ratio of increasing length with initial length
fused deposition method (Table 6). before the object is broken. That value shows the ductility of an object.
The most popular metallic 3D Printing techniques are Selective Laser The table shows that FDM has a lower elongation at break value than
Sintering and Selective Laser Melting Methods. Examples of the com­ DMLS or SLS. It means that an object made with FDM is more brittle.
mercial machine are EOSINT M 270, ProX200 SLM, Concept Laser Mlab Moreover, the object processed with FDM has a lower relative density
Cusing, ProX DMP 320, DTM Sinterstation 2000, and DiMetal-280 ma­ than that of DMLS or SLS. What’s more, DMLS or SLS has a higher
chine. The Laser power used ranges from 30 to 255 W, and the scanning hardness value and lower porosity than FDM.
speed used ranges from 300 to 1500 mm/s [90–94]. Below is The It plays such a vital role because density plays an important role in
Comparison of both Mechanical Properties (Table 7). reducing any internal defects [101]. When the object has a higher
The table above shows that there are three types of the materials, relative density and when it is denser than the other objects, it has lower
namely Stainless Steel 17-4PH, Stainless Steel 316 L, and Titanium Alloy porosity and more strength. There is no gap between each particle in the
Ti6Al4V. Each material is at least processed with two different additive internal structure, so it has a good bonding. Overall, FDM with a metallic
manufacturing techniques one of which is Fused Deposition Modeling material still needs improving on its mechanical properties. The poorer
(FDM) and one of the other is Selective Laser Sintering (SLS) or Direct situations result from the parameter not suitable to an object or not
Metal Laser Sintering (DMLS). These techniques have a different optimally processed in the post-manufacturing process.
manufacturing process. The FDM process started with the material went According to the data above, the capability of FDM to create a
through into the guide bush and heating room. Then the feed roller metallic part is an advantage of this technique also that has various
extrudes the material while the heating process is going on. The heat material availability, cheaper, compact size, and low working temper­
temperature should be higher than the melting point of the material. ature. The metallic printed part has a good enough quality, but the other
When the material is melted, it can flow into the nozzle and create an technique that more familiar with metallic material still better than
object. The SLS and DMLS has a same process, that started with placed FDM. It is the opportunity for us to find the gap and to improve them
the metal powder on the metal chamber. The metal will swipe with [102].

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Table 7
The Comparison of both Mechanical Properties.
Material and AM process

Mechanical Stainless steel (17-4PH) Stainless steel (316 L) Titanium alloy (Ti6Al4V)
Properties
FDM DMLS Process SLS FDM FDM SLS SLS Process FDM SLS Process
Process Process Process Process Process Process

Horizontal:530 ± Horizontal: 943 ±

Yield Strength Horizontal:590
800 620 – 194 ± 19 172,369 20 – 40
(MPa)
Vertical:550 Vertical:440 ± 20 Vertical: 925 ± 40
Horizontal:660 ± Horizontal: 1020 ±
1489,10
Tensile Strength 20 40
1050 1100 – 441 ± 27 482,633 –
(MPa) Horizontal:1100 Vertical: 1000 ±
Vertical:570 ± 20
Vertical:980 40
Elongation at Break Horizontal:39 ± 5 – Horizontal: 12 ± 2
5 25 ± 5 16 – 29,5 ± 3,8 30
(%) Vertical:49 ± 5 Vertical: 12 ± 3
Density (g/cm3) – 7,8 – – 7,63 4,95 – 7,65 8 – –
Relative density (%) 96 100 100 95 – – – – –
145,2 ± Horizontal: 368
Hardness (HV) 285 428 414 – 140 – –
6,7 Vertical: 372
Sa =
Horizontal: 4-6
Surface Roughness 19,008
– – – – – 5-10 –
(μm) Sq =
Vertical: 4-7
20,391
4,38 –
Porosity (%) 4,3 0,41 – 8 7,8 – 10.965 3.662
38,52
Length:20.3 Width:16,3
Shrinkage (%) Width:15.9 – – 17 – – – –
Height:17,4
Height:15.2
References [55,95] [90,96] [91,97] [57] [59] [92,98] [99] [78] [62,78,100]

Notes: FDM: Fused Deposition Modeling | DMLS: Direct Metal Laser Sintering | SLS: Selective Laser Sintering.

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